How to Make Your Own Wind Turbine From Scrap Materials

Introduction

Building my own wind turbine from scrap materials is an exciting project that allows me to generate electricity from the wind. A wind turbine converts the kinetic energy in the wind into rotational mechanical energy. This rotational energy can then be used to generate electricity.

Constructing a wind turbine from scrap materials is a great way to repurpose old or recycled items that would otherwise go to waste. It also allows me to build an electricity generating system with minimal costs. In this article, I will provide a step-by-step guide on how I can build my own small wind turbine using scrap materials readily available to me.

Materials Needed

To build a small wind turbine from scrap materials, I will need to gather the following items:

• Alternator - This converts the rotational energy into electrical energy. I can salvage this from an old car.

• Blades - I can use 3-4 wooden blades. These can be cut out of plywood, an old tabletop or wooden pallet.

• Hub - This attaches the blades to the alternator shaft. I can fabricate one using a wooden disk.

• Tail - The tail keeps the turbine facing into the wind. I can make this out of a sheet metal sheet or aluminum can.

• Frame - The frame provides support for the whole system. I can weld together metal scraps to create the tower frame.

• Bolts, screws and nuts - To assemble the various components. I can use salvaged hardware.

• Electrical wire - For connecting the alternator to a battery to store the generated electricity. I can strip old electrical cables.

• Battery - To store the generated electricity. A car battery will work well.

Tools Needed

To construct the wind turbine, I will need access to the following tools:

• Drill - For drilling holes in the blades, tail and frame.

• Sander - To smooth and shape the wooden blades.

• Jigsaw or handsaw - For cutting the wooden blades out of wood scraps.

• Welder - For welding the metal frame pieces together.

• Wrenches and screwdrivers - For assembling all the components.

Step-by-Step Construction

Follow these steps to construct a small wind turbine from scrap materials:

Step 1 - Build the Rotor

The rotor consists of the blades and central hub.

• Cut 3-4 blades out of plywood using a jigsaw or handsaw. The blades should be 18-24 inches long and 4 inches wide at the base. They should have an aerodynamic curved shape. Sand the blades to smooth out any rough edges.

• Using a wooden disk, construct a central hub for attaching the blades. Drill holes through this disk to match the holes in the alternator shaft.

• Mark and drill 3-4 holes in each blade near the base, spaced evenly for properly balancing the rotor.

• Attach the blades to the hub using bolts, washers and nuts through the pre-drilled holes.

Step 2 - Attach the Rotor to the Alternator

• Remove the pulley from the alternator shaft.

• Slide the alternator shaft through the hole in the wooden hub.

• Secure using a washer and nut. Tighten securely.

• Test spin the rotor slowly to ensure proper rotation.

Step 3 - Make the Tail

The tail keeps the turbine facing into the wind.

• Cut a rectangle out of a large sheet metal sheet or aluminum can. The tail should be around 2 ft x 1 ft in size.

• Drill 2 holes near the edges for attaching the tail.

• Bolt the tail onto the turbine frame using washers and nuts. Position it off-centered so the turbine properly orients itself.

Step 4 - Construct the Frame

• Weld scrap metal pieces together to form a square tower frame with four legs. This provides a strong base for mounting the wind turbine. Make the legs 2-3 feet long with wide footings.

• Include cross braces on the frame for lateral strength.

• On the top of the frame, weld a solid metal plate with a hole in the center to accept the alternator shaft. This mounts the rotor on the frame.

Step 5 - Final Assembly

• Mount the assembled rotor and alternator onto the top plate of the frame. Use washers and nuts to secure tightly.

• Connect the electrical wires from the alternator to a charge controller. Then connect wires from the charge controller to a battery to store electricity.

• Earth the system by connecting a ground wire from the frame to a metal grounding rod. This prevents electric shocks.

• Raise and mount the wind turbine on a tower structure and secure with guy wires.

• Position the turbine to face into the prevailing winds in your area.

Generating Power

Once constructed and assembled, the wind turbine will begin generating electricity as the rotor spins in the wind. The performance will vary based on wind speed, blade size and alternator type. But even a small wind turbine can generate useful electricity to charge batteries or power lights.

Proper maintenance involves checking and tightening bolts occasionally. The system also requires protection from very high winds. But the wind turbine should run maintenance-free for years, providing clean renewable power from the wind.

Conclusion

Building a scrap-built wind turbine is an environmentally friendly way to generate free electricity from the wind. This project repurposes waste materials and requires minimal costs. With some basic mechanical skills and the steps outlined in this article, I can successfully construct my own small wind turbine from recycled parts. Harnessing the wind to produce my own renewable power is incredibly rewarding.